Film forming mold, film forming method using mold, and film forming control system

ABSTRACT

When forming a film on a work, such as a lamp holder, the work is not set in a film-forming chamber as in the prior art, but a film is formed thereon by using a mold, thereby simplifying the film formation work. A movable mold is matched to a fixed mold in a state where a vacuum deposition apparatus, the film-forming element, is provided in the fixed mold and the work is supported in the movable mold. Next, film formation is carried out with the film-forming space in a vacuum state. Thereafter, the movable mold is opened, wherein the film formation work on the work surface using molds can be carried out with a series of processes.

This application is the U.S. National Stage of PCT/JP2004/006981, filedMay 17, 2004, which claims priority from JP2003-140060, filed May 19,2003, the entire disclosures of which are incorporated herein byreference thereto.

Further this application is related to the U.S. National Stage ofPCT/JP2004/006979, filed May 17, 2004, U.S. patent application Ser. No.10/557,475 filed Nov. 18, 2005, the entire disclosure of which isincorporated herein by reference thereto.

BACKGROUND

The disclosure relates to a film forming mold for various types ofmoldings including headlamps, direction indicators (including sideblinkers), tail lamps, etc., which are incorporated in a vehicle, etc.,a film forming method using the mold, and a film forming control system.

BACKGROUND ART

Generally, as such a type of molding, there is a molding, such as a lampbody of a headlamp for a vehicle, having a mirror-finished surface beinga reflection surface film-formed on the injection-molded molding toincrease the light amount and to secure a wider range of irradiation.However, conventionally, a lamp body is produced so that a lamp holderin which a bulb is incorporated and a lens portion formed of resinhaving transmittance are mold-matched, and the surfaces of themold-matched portions are adhered together. As such a production method,a mold-slide injection system has been known, for example, refer toJapanese Patent Application No. 62-087315, now Patent Publication No.Hei-2-38377. According thereto, after a lamp holder and a lens portion,which are primary products, are respectively injection-molded in a statewhere a movable mold and a fixed mold are disposed so as to be opposedto each other, the movable mold is caused to slide, and the respectiveprimary products are mold-matched to be matched to each other. Then, aresin material is secondarily injected to the mold-matched portions ofthe primary products, thereby integrally molding the lamp body.

SUMMARY

However, such a type of molding cannot cope with a case where areflection surface is formed on a lamp holder as described above.Therefore, in a case of film-forming the reflection surface, after thelamp holder, injection-molded using a mold, is removed from the mold, amultitude of corresponding removed lamp holders are set in afilm-forming chamber, and a reflection surface is formed on the innersurfaces of the corresponding multitude of moldings by using formingmeans, such as a vacuum deposition apparatus or a spattering apparatus.Thereafter, the lamp holder and lens portion are made integral with eachother.

However, because the film-forming chamber is provided to form films witha multitude of moldings set therein in order to increase efficiency, thearea of the chamber is caused to be larger. As a result, it not onlytakes more time to form a vacuum in the entire film-forming chamber, butalso it is necessary to form a vacuum more completely because there is along distance between a molded lamp holder and film-forming means.Therefore, there is a problem in that work efficiency is worse.

Furthermore, in a case where it is necessary to form a vacuum in thefilm-forming space for film formation, because an opening/closing meansis provided at the side of a vacuum pump, the cubic volume ranging fromthe opening/closing means to the film-forming space is enlarged, and thetime required for forming a vacuum in the film-forming space islengthened. Therefore, there is another problem in that work efficiencyis further worsened.

Still further, where film-forming work is carried out using a mold whichis not available in the prior art, where a vacuum is formed in thefilm-forming space, and atmospheric air is caused to flow in thefilm-forming space when opening the mold, there remains a question as toquickness of work and improvement in work efficiency. However, in theprior art, there has been no case where such matters are taken intoconsideration.

The following was developed to solve such problems in view of theabove-described situations.

A first aspect of the disclosure is a film-forming mold composed of afirst mold in which a work on which a film is formed is incorporated,and a second mold in which a film-forming means, to form a film on thework, is incorporated.

A second aspect of the disclosure is a film-forming mold wherein, inaddition to the first aspect, the second mold is a mold for molding awork.

A third aspect of the disclosure is a film-forming mold wherein, inaddition to the first or the second aspects, the first mold is a movabletype and the second mold is a fixed type.

A fourth aspect of the disclosure is a film-forming mold wherein, inaddition to any one of the first aspect through the third aspect, thefilm-forming means is a spattering apparatus or a vacuum depositionapparatus.

A fifth aspect of the disclosure is a film-forming mold wherein, inaddition to any one of the first aspect through the fourth aspect, thefilm-molding means is provided in a cylindrical recessed hole having abottom, which is formed in the second mold, and a film-forming space issecured between the film-forming means and the work.

A sixth aspect of the disclosure is a film-forming mold wherein, inaddition to any one of the first aspect through the fourth aspect, thefilm-forming means is provided so as to airtightly seal a through-holeprovided in the second mold, and a film-forming space is secured betweenthe film-forming means and the work.

A seventh aspect of the disclosure is a film-forming mold wherein, inaddition to any one of the first aspect through the sixth aspect, thesecond mold is provided with a vacuuming flow channel to make thefilm-forming space vacuum, and a first opening/closing means for openingand closing the vacuuming flow channel.

An eighth aspect of the disclosure is a film-forming mold wherein, inaddition to any one of the first aspect through the seventh aspect, thesecond mold includes a masking portion for masking a work attached tothe first mold.

A ninth aspect of the disclosure is a film-forming mold wherein, inaddition to any one of the first aspect through the eighth aspect, thefirst mold or the second mold is provided with an atmospheric air inletchannel for permitting atmospheric air to flow into the film-formingspace, and a second opening/closing means for opening and closing theatmospheric air inlet channel.

A tenth aspect of the disclosure is a film-forming mold wherein, inaddition to the ninth aspect, the atmospheric air inlet channel and thesecond opening/closing means are provided in an ejector means forremoving a film-formed work from the first mold.

An eleventh aspect of the disclosure is a film-forming mold wherein, inaddition to the ninth aspect or the tenth aspect, the second mold isprovided with a third opening/closing means for opening and closing afilm-forming space, which is positioned between the vacuuming flowchannel and the atmospheric air inflow channel.

A twelfth aspect of the disclosure is a film-forming method using amold, which comprises, at least, the sequential steps of mold matchingof a first mold in which a work on which a film is formed isincorporated and a second mold in which film-forming means to form afilm on the work is incorporated; film-forming for forming a film on awork; and opening the first mold and the second mold.

A thirteenth aspect of the disclosure is featured, in addition to thetwelfth aspect, in a film-forming method using a mold in which the firstmold is a movable type and the second mold is a fixed type.

A fourteenth aspect of the disclosure is featured, in addition to thetwelfth aspect or the thirteenth aspect, in a film-forming method usinga mold, wherein the film-forming means is a spattering apparatus or avacuum deposition apparatus.

A fifteenth aspect of the disclosure is featured, in addition to thetwelfth aspect through the fourteenth aspect, in a film-forming methodusing a mold, wherein a vacuuming step to make a vacuum in afilm-forming space between the film-forming means and a work is providedbetween the mold-matching step and the film-forming step.

A sixteenth aspect of the disclosure is featured, in addition to thefifteenth aspect, in a film-forming method using a mold, wherein thesecond mold is provided with a vacuuming flow channel communicating witha vacuum pump to make the film-forming space a vacuum, and firstopening/closing means for opening and closing the vacuuming flowchannel, and the vacuuming step is carried out by opening the firstopening/closing means.

A seventeenth aspect of the disclosure is featured, in addition to anyone of the twelfth aspect through the sixteenth aspect, in afilm-forming method using a mold, wherein the second mold is providedwith a masking portion for masking a work attached to the first mold,and the work is masked in the mold-matching step.

An eighteenth aspect of the disclosure is featured, in addition to thesixteenth aspect or the seventeenth aspect, in a film-forming methodusing a mold, wherein the first mold or the second mold is provided withan atmospheric air inflow channel for causing atmospheric air to flowinto the film-forming space, and second opening/closing means foropening and closing the atmospheric air inflow channel, and a firstopening/closing means closing step for closing the first opening/closingmeans and a second opening/closing means opening step for opening thesecond opening/closing means are provided between the film-forming stepand the mold-matching step.

A nineteenth aspect of the disclosure is featured, in addition to theeighteenth aspect, in a film-forming method using a mold, wherein theatmospheric air inflow channel and the second opening/closing means areprovided in an ejector means for removing a film-formed work from thefirst mold, and the second opening/closing means opening step is carriedout in line with removal of the work by the ejector means.

A twentieth aspect of the disclosure is featured, in addition to theeighteenth aspect, in a film-forming method using a mold, wherein theatmospheric air inflow channel is a mold-matching surface between thefirst mold and the second mold, and the second opening/closing meanscloses the atmospheric air inflow channel by mold matching in themold-matching step, and opens the atmospheric air inflow channel in themold-opening step.

A twenty-first aspect of the disclosure is featured, in addition to anyone of the sixteenth aspect through the twentieth aspect, in afilm-forming method using a mold, wherein the second mold is providedwith a third opening/closing means for opening and closing afilm-forming space between the vacuuming flow channel and the secondopening/closing means, and a third opening/closing means closing stepfor closing the third opening/closing means is provided during the stepsfrom the end of the film-forming step to the second opening and closingopening step.

A twenty-second aspect of the disclosure is featured in a film-formingmethod using a mold which comprises a first mold in which a work onwhich a film is formed is incorporated; a second mold in whichfilm-forming means for molding a film on the work in a vacuum state; avacuuming flow channel for making a vacuum of a film-forming spacebetween the film-forming means and the work; a first opening/closingmeans for opening and closing the vacuuming flow channel; and a secondopening/closing means for opening and closing the film-forming space forcommunication with the atmosphere; and the same method comprises thesteps of mold-matching the first mold in which the work is incorporatedand the second mold; making a vacuum of the film-forming space in astate where the second opening/closing means is closed and the firstopening/closing means is opened; film-forming by film-forming means in astate where the first opening/closing means is opened or closed and thesecond opening/closing means is closed; causing atmospheric air to flowinto the film-forming space in a state where the first opening/closingmeans is opened or closed and the second opening/closing means isopened; and opening the mold-matched molds.

A twenty-third aspect of the disclosure is featured in a film-formingmethod using a mold which comprises a first mold in which a work onwhich a film is formed is incorporated; a second mold in whichfilm-forming means for forming a film on the work in a vacuum state; avacuuming flow channel for making a vacuum of a film-forming spacebetween the film-forming means and the work; a first opening/closingmeans for opening and closing the vacuuming flow channel; a secondopening/closing means for opening and closing the film-forming space forcommunication with the atmosphere; and a third opening/closing means foropening and closing a film-forming space between the vacuum flow channeland the second opening/closing means; and the same method comprises thesteps of mold-matching the first mold in which the work is incorporatedand the second mold; making the vacuum in the film-forming space in astate where the second opening/closing means is closed and the first andthe second opening/closing means are opened; film-forming byfilm-forming means in a state where the first opening/closing means isopened or closed, the second opening/closing means is closed, and thethird opening/closing means is closed; causing atmospheric air to flowinto a space of the film-forming space nearer to the work side than thethird opening/closing means by opening the second opening/closing meansin a state where the first opening/closing means is opened or closed;and opening the mold-matched molds.

A twenty-fourth aspect of the disclosure is featured in a film-formationcontrolling system using a mold, comprising a means for forming a filmin a vacuum state; a means for actuating a mold for mold matching andopening of a first mold in which a work on which a film is formed isincorporated and a second mold in which the film-forming means isincorporated; and a first opening/closing means for opening and closinga vacuuming flow channel to make a vacuum in a film-forming spacebetween the film-forming means and the work; and simultaneouslyincluding a control portion, the control of which is established tosequentially carry out an output of a mold-matching operation command tothe mold-matching means; an output of an opening operation command tothe first opening/closing means; an output of a film-forming operationcommand to the film-forming means; an output of a film formationstopping command to the film-forming means; an output of a closingoperation command to the first opening/closing means; and an output of amold-opening operation command to the mold actuating means.

A twenty-fifth aspect of the disclosure is featured in a film-formationcontrolling system using a mold, comprising a means for forming a filmin a vacuum state; a means for actuating a mold for mold matching andopening of a first mold in which a work on which a film is formed isincorporated and a second mold in which the film-forming means isincorporated, and for opening the molds; and a first opening/closingmeans for opening and closing a vacuuming flow channel to make a vacuumof a film-forming space between the film-forming means and the work; andsimultaneously including a control portion the control of which isestablished to sequentially carry out an output of a mold-actuatingoperation command to the mold-matching means; an output of an openingoperation command to the first opening/closing means; an output of aclosing operation command to the first opening/closing means; an outputof a film-forming operation command to the film-forming means; an outputof a film formation stopping command to the film-forming means; and anoutput of a mold opening operation command to the mold actuating means.

A twenty-sixth aspect of the disclosure is featured, in addition to anyone of the twenty-third aspect through the twenty-fifth aspect, in afilm-formation controlling system using a mold, comprising anatmospheric air flow channel for causing atmospheric air to flow intothe film-forming space and a second opening/closing means for openingand closing the atmospheric flow channel, wherein the control portion isestablished to control so that an opening operation command is outputtedto the second opening/closing means simultaneously with or prior to theoutput of the mold opening operation command.

A twenty-seventh aspect of the disclosure is featured, in addition tothe twenty-sixth aspect, in a film-formation controlling system using amold, wherein a third opening/closing means for opening and closing afilm-forming space between the vacuuming flow channel and the secondopening/closing means is provided, and the control portion isestablished to control so that a closing operation command is outputtedto the third opening/closing means simultaneously with or prior to theoutput of an opening operation command to the first opening/closingmeans, and an opening operation command is outputted to the thirdopening/closing means simultaneously with or prior to the output of amold-opening operation command to the mold-actuating means.

According to the first aspect, it is possible to simply form a film on awork by using the first mold and the second mold.

According to the second aspect, because molds for molding a work can beeffectively used to form a film on the work, and at the same time, afilm is formed successively to molding the work, film formation can becarried out in a state where no fingerprints are attached to the surfaceof the work or there is no case where the work is brought into contactwith other members and is damaged.

According to the third aspect, because the second mold in whichfilm-forming means is incorporated is a fixed mold, members derived fromthe film-forming means, such as lead wires and piping led from(connected to) the film-forming means can be made stationary (immovable)when molding by the mold. Therefore, such members can be freed fromrepeated strain based on repeated folding and bending.

According to the fourth aspect, spattering and vacuum deposition can becarried out.

According to the fifth aspect, incorporation of film-forming means inthe second mold can be carried out from the mold-matching surface side.

According to the sixth aspect, incorporation of film-forming means inthe second mold can be carried out from the side opposite themold-matching surface side.

According to the seventh aspect, because the second mold is providedwith a vacuuming flow channel and first opening/closing means foropening and closing the vacuuming flow channel, the second mold can besimplified, and at the same time, the cubic volume at the film-formingspace side from the first opening/closing means can be made smaller thanin a case where the first opening/closing means is provided at thevacuum pump side, wherein the time required for securing a vacuum statecan be shortened, and work efficiency can be improved.

According to the eighth aspect, masking of a work can be carried out byeffectively using the second mold in which film-forming means isprovided.

According to the ninth aspect, because the molds can be opened in astate where atmospheric air flows into the vacuumed film-forming space,the molds can be smoothly and gently opened.

According to the tenth aspect, inflow of atmospheric air can be carriedout by effectively using ejector means secured to remove a film-formedwork from the first mold.

According to the eleventh aspect, it is possible that the film-formingmeans side of the film-forming space from the third opening/closingmeans between the vacuuming flow channel of the film-forming space andthe atmospheric air flow channel can be maintained in a vacuum state.

According to the twelfth aspect, it becomes possible to form a film byusing a mold for a work.

According to the thirteenth aspect, because the second mold in which thefilm-forming means is incorporated is a fixed mold, and members derivedfrom (connected to) the film-forming means, such as lead wires andpiping, etc., are not brought into contact with the molding molds andcan be made stationary (immovable), the members can be freed from anyrepeated strain generated due to repeated folding and bending.

According to the fourteenth aspect, spattering and vacuum deposition maybe applicable.

According to the fifteenth aspect, vacuuming can be easily achieved in afilm-forming space when spattering and vacuum deposition are carriedout.

According to the sixteenth aspect, the vacuuming flow channel secured inthe second mold can be opened and closed by the first opening/closingmeans, wherein the second mold can be simplified, and at the same time,the cubic volume at the film-forming space from the firstopening/closing means can be made smaller than in the case where thefirst opening/closing means is provided at the vacuum pump side. And,the time required for vacuuming can be shortened, and work efficiencycan be improved.

According to the seventeenth aspect, masking of a work can be carriedout by effectively using the second mold in which film-forming means isincorporated.

According to the eighteenth aspect, because the film-forming space,which is under vacuum conditions when forming a film, is opened withatmospheric air flowing in, the mold can be smoothly and gently opened.

According to the nineteenth aspect, atmospheric air can flow in byeffectively using the ejector means provided to remove a film-formedwork from the first mold.

According to the twentieth aspect, it is possible to cause atmosphericair to flow into the film-forming space that is under a vacuumedcondition, without forming an exclusive atmospheric air flow channel andany second opening/closing means.

According to the twenty-first aspect, it is possible that thefilm-forming means side of the film-forming space from the thirdopening/closing means, between the vacuuming flow channel of thefilm-forming space and the atmospheric air flow channel, can bemaintained in a vacuum state.

According to the twenty-second aspect and the twenty-third aspect, aseries of film-forming processes of a work, in which a film is formedwith the film-forming space in a vacuum condition, can be continuouslycarried out.

According to the twenty-fourth aspect and the twenty-fifth aspect, filmformation on a work can be automatically carried out by using thecontrol portion.

According to the twenty-sixth aspect, inflow of atmospheric air into thevacuum state film-forming space can be automatically controlled whileopening the mold after a film is formed.

According to the twenty-seventh aspect, the space at the film-formingmeans side of the film-forming space from the third opening/closingmeans can be automatically controlled so that the space can bemaintained in a vacuum state with the mold opened.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will be made with reference to the drawings in which:

FIG. 1 is a longitudinal, cross-sectional view showing a side directionindicator (side blinker);

FIGS. 2(A) through 2(C) are schematic, cross-sectional views showing theprocesses of the primary injection;

FIGS. 3(A) through 3(C) are schematic, cross-sectional views showing theprocesses of the secondary mold matching;

FIGS. 4(A) through 4(C) are schematic, cross-sectional views showing theprocesses to add a lamp holder to a lens portion;

FIGS. 5(A) through 5(C) are schematic, cross-sectional views showing theprocesses for removal of a lamp body;

FIGS. 6(A) and 6(B) are schematic, cross-sectional views showing a moldportion according to a second embodiment;

FIG. 7 is a block circuit diagram showing a controlled state accordingto the second embodiment;

FIG. 8 is a flowchart showing a part of the control process according tothe second embodiment;

FIG. 9 is a flow chart showing the first remaining processes in thecontrol process according to the second embodiment;

FIG. 10 is a flow chart showing the second remaining processes in thecontrol process according to the second embodiment;

FIG. 11 is a schematic, cross-sectional view of a mold-matched moldportion according to a third embodiment;

FIG. 12(A) is a schematic, cross-sectional view showing a mold portionin a half-removed state of a work according to the third embodiment, andFIG. 12(B) is an enlarged sectional view showing a vertical facialregion of a mold;

FIG. 13 is a block circuit diagram showing a controlled state accordingto the third embodiment; and

FIG. 14 is a flow chart showing the control process according to thethird embodiment.

DETAILED DESCRIPTION OF EMBODIMENTS

Next, a description is given of a first exemplary embodiment withreference to FIGS. 1 through 5. In the drawings, reference number 1denotes a movable mold (the first mold), and 2 denotes a fixed mold (thesecond mold). The movable mold 1 is movable (to be separated from andcontacted to) in opposite directions with respect to the second mold 2and is also structured to be movable in the direction along the face ofthe fixed mold 2 (parallel or lateral movement) in a state apart fromthe fixed mold 2. However, as technology used for prior art mold slideinjection can be employed, as it is, for the detailed movementmechanism, a detailed description thereof is omitted. Also, becausemovement of the molds may be relative to each other, it may be such thatthe first mold is fixed and the second mold is movable. Further, it is amatter of course that both the molds are structured to make relativemovement. In addition, if the movement is movement in the directionalong the facial region, the movement may not only be parallel movementin the linear direction but also rotating movement centering around anaxis. Examples of movement control of the molds 1, 2 will be describedlater.

Formed in the movable mold 1 are a concave mold surface 1 a, for formingthe outside face of a lamp holder 3 (corresponding to a “work” of theinvention), and a convex mold surface 1 b, for forming the inside faceof a lens portion 4. A convex mold surface 2 a, for forming the insideface of the lamp holder 3, and a concave mold surface 2 b, for formingthe outside face of the lens portion 4, are formed in the fixed mold 2.Further, a concave mold surface 2 c is formed in the fixed mold 2, asfilm-forming means. The mold surface 2 c accommodates (internallyincludes) a vacuum deposition apparatus 5 as employed in the presentembodiment. The concave mold surface 2 c is formed between the convexmold surface 2 a, for forming the inside face of the lamp holder 3, andthe concave mold surface 2 b, for forming the outside face of the lensportion 4. Although a publicly known vacuum deposition apparatus 5 isemployed, the vacuum deposition apparatus 5 is briefly described. Thevacuum deposition apparatus 5 is provided with a vacuuming flow channel6 connected to a vacuum pump P via the first opening/closing valve 6 a,a boat (target) 7 in which metal (for example, aluminum and chromium) tobe deposited is accommodated, and a heater 8 for heating the boat 7.

A lamp body 9 is a side blinker in this described exemplary embodiment.A terminal 10 and a bulb 11 are incorporated therein as necessarycomponents. The lamp body 9 is composed of the lamp holder 3, moldedwith a non-translucent resin material, and a lens portion 4, molded witha translucent resin material. As described later, after the lamp holder3 and the lens portion 4 are molded by the primary injection moldingprocess, the movable mold 1 is moved (mold-slid), wherein the lampholder 3 and the lens portion 4 are mold-matched. A resin material 12 isthen secondarily injection-molded along the mold-matched face portionsso the components are integrated to produce the lamp body 9.

A method for producing the lamp body 9 will now be described withreference to the drawings. FIG. 2(A) shows that, with respect to boththe molds 1, 2, the mold surfaces 1 a, 2 a for forming the lamp holder3, and the mold surfaces 1 b, 2 b for forming the lens portion 4 areopposed to each other in a state spaced from each other (that is, withthe molds opened). The movable mold 1 is moved to the fixed mold 2 sidefrom the state of being spaced from each other, and the mold surfacesopposing each other are mold-matched (primary mold-matching process:Refer to FIG. 2(B)). In the mold-matched state, primary injectionmolding is carried out, wherein the lamp holder 3 and the lens portion 4are injection-molded, respectively (primary injection molding process:Refer to FIG. 2(C)).

Thereafter, as shown in FIG. 3(A), a mold releasing (mold-opening)process, in which the movable mold 1 is moved in the direction such thatthe movable mold 1 is released, or opened, from the fixed mold 2. Atthis time, the molds are designed so that the lamp holder 3 is supported(remains) in the movable mold 1 without being released, and the lensportion 4 is supported (remains) in the fixed mold 2 side without beingreleased. Next, after the movable mold 1 moves laterally (refer to FIG.3(B)) so that the lamp holder 3 is opposed to the vacuum depositionapparatus 5, the movable mold 1 moves to the fixed mold 2 side and ismold-matched (secondary mold-matching process: Refer to FIG. 3(C)), anda film-forming space S, formed between the interior of the concave moldsurface 2 c and the lamp holder 3 opposed thereto, is sealed from theatmosphere.

In a state where both of the molds 1, 2 are apart from each other beforeor after making the parallel, or lateral, movement, a masking, orcovering, member 13 for masking (covering) portions that are not to bevacuum-deposited, that is, portions for receiving both the terminal 10and an insertion portion 11 a of the bulb 11, that are part of the lampholder 3 (masking member incorporating process). The masking memberincorporating process is then carried out. In the embodiment, themasking member 13 is incorporated at a stage before making parallelmovement. Also, the molds are designed so that the peripheral portion 2d, at the opening side of the concave mold surface 2 c that internallyincludes the vacuum deposition apparatus 5, masks the mold-matchingsurface 3 b, that attaches the lamp holder 3 to the lens portion 4, andthe mold-matching surface 3 b is not vacuum-deposited.

After the sealed film-forming space S is formed in a mold-matched statewhere the lamp holder 3 and the vacuum deposition apparatus 5 areopposed to each other, the first opening/closing valve 6 a is opened,air in the film-forming space S is removed from the vacuum flow path 6to cause the interior of the film-forming space S to become a vacuum. Inthis state, molten metal supplied to the boat 7 is evaporated by theheater 8, wherein the metal is vacuum-deposited on an exposed innersurface of the lamp holder 3, and a reflection surface 14 is film-moldedfilm, or reflection surface, forming process of FIG. 4(A)). Next, afterthe film is formed, the movable mold 1 is released (mold-opened) fromthe fixed mold 2 (FIG. 4(B)). Thereafter, the movable mold 1 is moved inparallel to the fixed mold 2 to cause the lamp holder 3 and the lensportion 4 to be opposed to each other (FIG. 4(C)). In this connection,before and after moving the movable mold 1 in parallel, a process forremoving the masking member 13 and a process for incorporating theterminal 10 and the bulb 11, as necessary components, are carried out.In the embodiment, in the process where a mold-releasing step isfinished before making parallel movement, the above-described removingprocess and incorporating process are carried out. In addition, althoughthe film-forming space S is a vacuum, the molds are opened by anoperation force of a mold-opening action of the movable mold 1 becausethe film-forming space S is small, wherein atmospheric air is caused toflow into the film-forming space S.

After that, the movable mold 1 is moved to the fixed mold 2, and thelamp holder 3 and the lens portion 4 are mold-matched (thirdmold-matching process of FIG. 5(A)). A resin material 12 is secondarilyinjected to the mold-matched surface between the lamp holder 3 and thelens portion 4 (secondary injection molding process of FIG. 5(B)),whereby the lamp holder 3 and the lens portion 4 are integrated, and alamp body 9 having a reflection surface 14 formed thereon is formed.Then, the movable mold 1 is spaced from the fixed mold 2, and the moldedlamp body 9 is removed (released from the mold; FIG. 5(C)). After that,the movable mold 1 moves in parallel to the initial position of FIG.2(A). Subsequently, the process is repeated.

In the just described embodiment, when producing the lamp body 9,because a film-forming process for forming a reflection surface 14 onthe inner surface of the lamp holder 3 is provided between the primaryinjection molding process for forming the lamp holder 3 and the lensportion 4 and the secondary injection molding process for integratingthe lamp holder 3 and the lens portion 4, any work for removing the lampholder 3 and resetting the same is no longer required as it was in theprior art. In the prior art it was also necessary that, after areflection surface was formed on the lamp holder 3 once removed from themold, the lamp holder 3 needed to be set in the mold again thereafter.However, in the embodiment, it is possible to produce the lamp holder 3and to form a film for the reflection surface in a series of moldsliding processes, wherein work efficiency can be improved. Furthermore,because it is not necessary that the lamp holder 3 be removed and reset,there is no case where fingerprints can adhere to the reflection surface14 by touching the same or that the reflection surface is damaged due tobeing brought into contact with any other materials, wherein thegeneration of defects can be reduced to a large extent.

Still further, in the embodiment, in the film-forming process, the outersurface of the lamp holder 3 (that is, the surface covered by the firstmold 1) is supported, as it is, in the movable mold 1 without beingreleased therefrom, that is, is completely hidden from the outside,wherein the first mold 1 itself functions as a masking member withrespect to the outer surface of the lamp holder 3 (the surface when thelamp holder is made into a final product), and there is no case whereany film is formed on the outer surface of the lamp holder 3.Furthermore, in this case, because the concave mold surface 2 c in whichthe vacuum deposition apparatus 5 body is accommodated is formed on thesecond mold 2, that is a fixed mold, the vacuum deposition apparatus 5is fixed, wherein, as in the case where the vacuum deposition apparatus1 is installed in the movable mold 1 side, it is not necessary to employa structure for which movement of pump piping and wiring must be takeninto consideration. Therefore, the structure is simplified along withimproved durability.

Still further, in the embodiment, because, if a reflection surface ofmetal film is formed on portions where the reflection surface is notdesired to be formed, that is, on the portions where the terminal 10 andthe bulb 11 are attached, insulation is, spoiled and circuits areshorted, those portions are filled by the masking member 13, and thereflection surface 14 is formed. Therefore, a lamp body 9 that is freefrom any problem of short-circuiting can be produced. Furthermore, inthe embodiment, because the terminal 10 and the bulb 11 are incorporatedafter removing the masking member 13 after the reflection surface 14 isformed, all the production work, including film formation, can besmoothly carried out in a series of mold-sliding processes. As a result,it is possible to efficiently produce the lamp body 9.

Still further, although the lamp body 9 is structured so that themold-matching portion between the lamp holder 3 and the lens portion 4are cemented, or adhered, together in the secondary injection moldingprocess, when forming a film in the lamp holder 3, the cementing portion3 b is masked by the peripheral portion 2 d at the opening side of theconcave mold surface 2 c in which the vacuum deposition apparatus 5 bodyis accommodated. Therefore, there is no case where a film is formed onthe cementing portion 3 b. As a result, it is not necessary to use anyexclusive masking member 13 with respect to masking the cementingportion 3 b with the lamp holder 3 held in the first mold 1, as thecementing portion 3 b is masked by using the second mold 2. Thus, thereis no case where a film is formed on the portion molded in the secondaryinjection molding process, and the lamp holder 3 and the lens portion 4can be securely adhered to each other, wherein work efficiency can beincreased.

Also, because the concave mold surface 2 c for accommodating the vacuumdeposition apparatus 5 body, which is formed in the fixed mold 2, isdisposed between the mold surfaces 2 a, 2 b on which the lamp holder 3and the lens portion 4 are formed, the direction along which the movablemold 1 moves from the primary injection molding process to thereflection surface forming process becomes identical to the directionalong which the movable mold 1 moves from the reflection surface formingprocess to the secondary injection molding process. As a result, thereis an advantage in that the structure of the mold-sliding mechanism canbe simplified.

In addition, the disclosure is not limited to the above-describedembodiment, and the film formation is not limited to a reflectionsurface, such as a mirror-like surface, but it may be film formationbased on painting, etc. Furthermore, the film-forming means is notlimited to an vacuum deposition apparatus. Various types of knownfilm-forming apparatuses may be employed, in which a physical vapordeposition method (PVD) such as spattering deposition, etc., a chemicalvapor deposition method (CVD) such as thermal deposition and plasmadeposition, etc., are available. In addition, in the case of a moldingsuch as a lamp holder, the molding may be made into such a type in whichaccessories such as a terminal and a bulb, etc., are installed aftermolding. Further, in the film-forming means, the color of a film formedmay be varied based on a type of metal (for example, copper, aluminum,nickel, etc.) being a target, the degree of vacuum and the type offilling gas.

Also, although the embodiment is produced by injection molding as amolding process, the process is not limited to such molding process. Itmay be embodied in a commonly known molding technique, such as, forexample, press molding, blow molding, etc. Still further, if, forinstance, a description is given of a case where the final product is acompleted lamp body, the disclosure is applicable to a case where thelamp body is not continuously molded to the end as in the presentembodiment, rather an intermediate product in which a mirror-likesurface 14 is formed on the lamp holder 3 is molded, and the molding isreleased from a mold and is used as a component. Also, the film-formingmeans may be not only provided in the same mold as the mold for forminga surface which becomes a mirror-like surface, but also provided in adifferent mold.

In addition, with respect to the mold, an example in which two moldscomprising the first mold and the second mold are employed was describedin the above-described embodiment. Where a molding has a complicatedshape, which cannot be molded using only two molds, it is possible toincrease the number of molds as necessary, for example, a third mold, afourth mold, etc. In this case, it is a matter of course that theinvention can be embodied if the invention is structured so that maskingis carried out with at least one of the molds.

Furthermore, a description is given of a second embodiment withreference to FIGS. 6 through 10. The second embodiment is such that afilm surface 19 is formed on an exposed surface of a work (molding) 16incorporated in the first mold 15, which is a movable mold, using aspattering apparatus 18 incorporated in the second mold 17, which is afixed mold. A description is concurrently given of control procedurestherefore.

While a mold surface 15 a for incorporating and supporting a work 16 isformed in the first mold 15, a through-hole 17 a for incorporating thespattering apparatus 18, which employs an argon gas as an inactive gas,is drilled in the second mold 17. The spattering apparatus 18, insertedfrom the outside of the through-hole 17 a, is sealably attached to thesecond mold 17 via tightening bolts 18 a. In this case, the first mold15 molds the work (lamp holder) 16 as in the first mold 1 according tothe first embodiment, and the mold surface 15 a may be formed as in thecase of the mold surface 1 a of the first embodiment. The first mold 15is set so as to be tightened and released, wherein an actuator, such asa hydraulic cylinder, may be used as an operation actuator 20.

On the other hand, a film-forming space X is formed between thespattering apparatus 18 and the work 16 in a state where the first mold15 and the second mold 17 are matched to each other. A cylindricalvacuuming flow channel 21, communicating with and connected to a vacuumpump p is drilled in the second mold 17 nearer than the spatteringapparatus 18 to the work 16 side. Further, in the second mold 17, thefirst opening/closing valve (corresponding to the first opening/closingmeans of the invention) 22 is provided to open and close the vacuumingflow channel 21. The first opening/closing valve 22 may be anelectromagnetic valve, a hydraulic pilot valve, or any universal valvein the present embodiment. Therefore, the detailed structure thereof isomitted. Herein, it is assumed, for the following description, that anactuating means, such as an electromagnetic solenoid or a hydraulicvalve changing means, etc., is employed as the first actuator 23 foropening and closing the first opening/closing valve 22.

Further, an atmospheric air communicating channel 24, communicating withthe atmospheric air, is provided in the second mold 17 more toward thefirst mold 15 side than the vacuuming flow channel 20. The secondopening/closing valve 25 for opening and closing the atmospheric aircommunicating channel 24 is provided therein. Also, the thirdopening/closing valve 26, for opening and closing the film-forming spaceX, is provided between the atmospheric air communicating channel 24 andthe vacuuming flow channel 20. With respect to the second and thirdopening/closing valves 25, 26, it is assumed in the followingdescription that, as in the first opening/closing valve 22, the secondand third actuators 27, 28 are employed as operating means, such as anelectromagnetic solenoid or a pilot valve changing means, to carry outthe opening and closing operations of the second and third opening andclosing valves 25, 26. In addition, a masking portion 17 b, for maskingthe peripheral edge portion of the work 16, is formed, as shown in FIG.6(B), in the second mold 17.

Reference number 29 denotes a control portion that could be any one ofvarious types of devices, such as a microcomputer, etc. The controlportion 29 outputs control commands, which will be described later, tothe respective actuators 20, 23, 27, 28. Various detection signals areinputted into the control portion 29, which come from a workincorporation detection sensor 30 for detecting whether a work 16 isincorporated in the first mold 15, a mold status detection sensor 31 fordetecting whether the second mold 17 is located at a mold-matchedposition or at a mold-opened position with respect to the first mold 15,the first through third opening/closing detection sensors 32, 33, 34 forrespectively detecting opening and closing of the first through thirdopening/closing valves 23, 27, 28, and a film-forming conditionaccomplishment detection sensor 35 for detecting whether thefilm-forming space X meets the film-forming conditions (the film-formingsituations).

Herein, for example, if a series of molding processes carry out moldingand film formation with respect to the work 16 as in the firstembodiment, the work incorporation detection sensor 30 recognizeswhether the molding process is carried out, and detects incorporationbased on a judgment that the molding process has been carried out.Further, where a separately film-formed work 16 is incorporated in thefirst mold 15, or a masking member is incorporated in a work 16 moldedby molding, a sensor may be directly provided in the first mold 15 inorder to directly detect the work 16 incorporated in the first mold 15.However, such a mode may also be available in which an apparatus forincorporating a work or a masking member is composed of, for example, arobot (not illustrated) including an incorporation arm, and a detectionsensor for detecting the presence or absence of a work 16 is provided inthe corresponding incorporation arm, wherein it is detected whether thework 16 is incorporated in the first mold 15.

In addition, the mold status detection sensor 31 may be embodied as, forexample, a detection sensor (two-point position detection sensor) fordetecting whether the first mold 15 is located at a mold-matchedposition or a mold-opened position. However, respective exclusivesensors for separately detecting these positions may be used.

Further, the opening/closing detection sensors 32, 33, 34 may beembodied by using sensors for detecting whether the correspondingoperation actuators 23, 27, 28 are turned on or off. Still further, thefilm-forming condition accomplishment detection sensor 35 judges whetherthe film-forming space X reaches a vacuum state necessary for filmformation. The sensor 35 may be carried out by using a barometer(capable of detecting the degree of vacuum) disposed, for example, inthe vacuuming flow channel 21 (either at the vacuum pump P side or atthe film-forming space X side with respect to the first opening/closingvalve 22) or a tubing channel 21 a extending between the vacuum pump Pand the vacuuming flow channel 21. Also, in the embodiment, it isassumed that the vacuum pump P always operates by means of a switch-on.However, it is a matter of course that the vacuum pump P may becontrolled so as to be driven, for example, only in the film formationcontrolling process.

Next, with respect to the film formation controlling process by means ofthe control portion 29, a description is given of the second embodimentusing the block circuit diagram shown in FIG. 7 and the flowcharts ofFIGS. 8 through 10. In the drawings, with respect to the control portion29, the initial setting for the beginning operation is carried out, inwhich power is switched on, the system is started, necessary data areread, and actuators are set to the initial state. In the initial statein the present embodiment, it is assumed that initial control is carriedout, by which the first mold operating actuator 20 is set to amold-opened state, the first and the third opening/closing valveoperation actuators 23, 28 are set to a closed state, and the secondopening/closing valve operation actuator 27 is set to an open state.

And, in the film formation controlling process, first, the controlportion 29 carries out judgment whether a work 16 is incorporated in thefirst mold 15, based on a detection signal from the work incorporationdetection sensor 30. Where the control portion 29 judges that the work16 is incorporated, the control portion 29 outputs a control command tothe first mold operation actuator 20 for a mold-matching operation, andwhen the mold status detection sensor 31 detects that the first mold 15is positioned at a mold-matched position, the control portion 29 outputsa closing control command to the second opening/closing valve actuator27. Corresponding thereto, the second opening/closing valveopening/closing detection sensor 33 inputs a closing signal of thesecond opening/closing valve 25. Thereafter, the control portion 29outputs an opening control command to the first and the thirdopening/closing valve operation actuators 23, 28, thereby causing thefilm-forming space X to communicate with the vacuum pump P and to createa vacuum in the film-forming space X. Then, the film-forming conditionaccomplishment detection sensor 35 detects whether the film-formingspace X is a vacuum.

In addition, output of the closing control command to the secondopening/closing valve actuator 27 may be issued prior to themold-matching process. However, if the output is issued after themold-matching process, as in the present embodiment, the pressure in thefilm-forming space X, sealed in the mold-matching process, can bebrought into an atmospheric state. Thus, there is an advantage in thatit is possible to prevent the time required for creating a vacuum in thevacuuming process from being lengthened. That is, if the mold matchingis further intensively carried out in an almost sealed state in thefinal state of mold matching, the cubic volume of the film-forming spaceX is made smaller. As a result, the pressure in the film-forming space Xis made higher than the atmospheric pressure, as in the case where thevalve is closed prior to the mold-matching process.

FIGS. 9 and 10 shows control procedures for two control modes after thefilm formation conditions are reached. First, in the embodiment shown inFIG. 9, a control command of film-forming operation is outputted to thefilm-forming apparatus 18, wherein a film formation operation is carriedout. The film-forming process is carried out for the period of afilm-forming time preset as the time of completion of film formation,and is controlled to stop. After that, a closing operation command isoutputted to the first and the third opening/closing valve actuators 23,28. When it is detected by the respective corresponding first and thirdopening/closing detection sensors 32, 34 that the first and the thirdopening/closing valves 22, 26 are closed, an opening operation commandis outputted to the second opening/closing operation actuator 27. Whenit is detected by the second opening/closing detection sensor 33 thatthe corresponding second opening/closing valve 25 is opened, a controlcommand for a mold-opening operation is outputted to the first moldoperation actuator 20. When the mold opening is detected by the moldstatus detection sensor 31, the series of film-forming processes isterminated, wherein a removal process of the work 16 on which a film andfurther mold-molding processes as in the first embodiment are commenced.After these processes are completed, the status is controlled so thatthe initial control state in which the above-described initial settingsare terminated is reset.

By employing such a mode thus controlled, it is possible to continuouslyform a film on the work 16 through a series of control processes byusing the molds 15, 17. Further, the film-forming work can be simplifiedby achievement in which the process is repeatedly executed. And,because, in the embodiment, the first and the third opening/closingvalves 22, 26 are closed in the process prior to the mold-openingprocess, and the second opening/closing valve 25 is opened in themold-opening process, atmospheric air flows into the film-forming spaceX at the work side between the third opening/closing valve 26 and thework 16 for which the mold is opened. As a result, the film-formingspace X is brought to atmospheric pressure while the film-forming spaceX at the film-forming apparatus 18 side between the film-formingapparatus 18 and the third opening/closing valve 26 is maintained in avacuum state. Accordingly, when mold opening, it is not necessary tocarry out a forced mold opening operation in a vacuum state as in thefirst embodiment, wherein the molds are smoothly and gently opened underthe atmospheric pressure.

Further, because the film-forming space X at the film-forming apparatusside, between the film-forming apparatus 18 and the thirdopening/closing valve 26, is maintained in a vacuum state when the moldsare opened, the reduced air in the film-forming space X at the work sidebetween the third opening/closing valve 26 and the work 16 makes iteasier to secure a vacuum state when carrying out the next film-formingoperation. Therefore, there is an advantage in that the vacuumingprocess to bring the entire film-forming space X into the film-formingconditions can be carried out in a short time and work efficiency can beimproved.

Where the present second embodiment is as described above, thefilm-forming space X at the film-forming apparatus 18 side is closed bythe third opening/closing valve 26 at least from the mold-openingprocess to the mold-matching process, the first opening/closing valve 22may no longer be necessary. However, at the stage of commencing theoperation, if the vacuum pump P is actuated in advance in a state wherethe first opening/closing valve 22 is closed in the stage to the moldmatching, the flow channel from the first opening/closing valve 22 tothe vacuum pump P can be made a vacuum in advance. Thus, because thevacuuming flow channel 21 located at the film-forming space X side withrespect to the first opening/closing valve 22 and the correspondingfilm-forming space X are only made a vacuum in the vacuuming process,the vacuuming process can be carried out in a shorter time. After thebeginning film-forming process is completed, control can be carried outwith the first opening/closing valve 22 opened.

Next, the embodiment shown in FIG. 10 differs from the above-describedembodiment in that the first opening/closing valve 22 is controlled tobe closed in the process prior to the film-forming process. Thereby,because the first opening/closing valve 22 is closed in the film-formingprocess, the film-forming space X is not influenced by the pulsationgenerated by an absorption operation of the vacuum pump P, and filmformation is carried out in a still state, wherein there is an advantagein that a more uniform and accurate film formation can be achieved.

In addition, the invention may be embodied without the thirdopening/closing valve 26 as in a third embodiment, shown in FIGS. 11 and12. In this case, because atmospheric air flows into the entirefilm-forming space X in the mold opening process, the third embodimentis slightly inferior to the second embodiment in that the time requiredto reach the film-forming conditions (to reach a vacuum state) islengthened in the vacuuming process. However, this does not constitute aproblem in which the film-forming space X is small.

The above-described third embodiment is provided with the first mold 36and the second mold 37 and differs from the second embodiment in thatneither masking portion for masking the peripheral portion of the work16 nor the third opening/closing valve 26 are provided in the secondmold 37. In the third embodiment, the first mold 36 is provided with anejector body (ejector means) 38, whose depiction and description isomitted in the first mold and the second mold, wherein prior to the moldopening or simultaneously therewith after the film-forming process, theejector body 38 is caused to protrude from the mold surface and causesthe work 16 to be removed from the first mold 36. However, anatmospheric air inflow channel 40 is formed in an insertion channel 39through which the ejector body 38 can be retracted and seated. In thiscase, in a state where the ejector body 38 is retracted and the moldsare not released, the atmospheric air inflow channel 40 is closed by atip end portion 38 a (corresponding to a second opening/closing means)of the ejector body 38 to stop atmospheric air flow into thefilm-forming space X (FIGS. 11 and 12(A)). However, as soon as theejector body 38 is unseated and moved to a provisional removing posturefor the work 16 from the molds, the atmospheric air inflow channel 40 isopened to permit atmospheric air to flow into the vacuumed film-formingspace X. Also, the ejector body 38 may completely remove the work 16from the molds. However, in this case, because the work 16 is freed fromthe first mold 16, there is a problem in that, when opening the molds,the work 16 is dropped from the first mold 36. Therefore, the work 16 ishalf removed from the first mold 36, that is, it is in a provisionallysupported state where a part of the work 16 is left in the first mold 36before it is completely removed from the mold, that is, in ahalf-removed state; whereby there is an advantage in that the work 16can be prevented from dropping when opening the mold. In the modeaccording to the embodiment, it is possible to carry out thehalf-removing operation and a full-removing operation when taking thework 16 out of the mold.

In this connection, where the first mold 36 is provided with verticalmold surfaces 36 a, 36 b that support the work 16, it is common in thefield of mold formation that a slightly tapered section (taper forremoval) which is widened toward the open end of the mold so that thework 16 can be easily removed is formed on the substantially verticalmold surfaces 36 a, 36 b (FIG. 12(B)). And, in this case, such anadvantage is brought about by means of a slight clearance Y which isproduced between the tapered section and the work 16 and functions as anatmospheric air inflow channel, and inflow of atmospheric air can beachieved. In addition, it is not necessarily required that the pressurein the film-forming space X is set to the atmospheric pressure whenopening the mold, wherein it is a matter of course that, if the pressurepermits atmospheric air to flow in and the internal pressure is lowerthan the atmospheric air pressure, this contributes to a lightening inoperation load for opening the mold.

And, in such a mode, it is not necessary that an exclusive atmosphericair inflow channel and the second opening/closing valve are provided asin the second embodiment. Such an advantage is brought about, by whichinflow of atmospheric air can be controlled by effectively using theejector body 38 and the inflow channel 40 provided to bring in andretract the ejector body 38. This is convenient.

Herein, FIGS. 13 and 14 depict a block circuit diagram and a flowchart,respectively, for a case where the ejector body 38 is employed. In thismode, inputted into the control portion 40 are detection signalsoutputted from the ejector posture detection sensor 41 for detecting thestatus of the ejector body 38 in addition to the same work incorporationdetection sensor 30, mold status detection sensor 31, firstopening/closing valve opening/closing detection sensor 32, andfilm-forming condition accomplishment detection sensor 35 as of thesecond embodiment. On the other hand, the control portion 40 outputs acontrol command to the ejector operation actuator 42 in addition to thefirst mold operation actuator 20, the first opening/closing valveoperation actuator 23, and the film-forming apparatus 18.

Herein, the ejector posture detection sensor 41 may be of a type that iscapable of detecting movement by which the ejector 38 is unseated andretracted. However, the ejector posture detecting sensor 41 may beembodied as a type capable of judging the status by reading a controlsignal outputted to the operation actuator 42 of the ejector body 38.

In FIG. 14, when the system is started and initial setting is commenced,a signal whether the work 16 is incorporated is inputted by the workincorporation detection sensor 30, and when a detection signal that thework 16 is incorporated is inputted in the control portion 40, thecontrol portion 40 outputs a mold matching control command to the firstmold operation actuator 20. Simultaneously, the mold status detectionsensor 31 judges whether the first mold 36 is in a mold-matched state,by which mold-matching control of the first mold 36 is carried out. Whenit is judged that the first mold 36 is matched, an opening commandsignal is outputted to the first opening/closing operation actuator 23.A detection signal that the first opening/closing valve 22 has beenopened is inputted into the control portion 40 by the firstopening/closing detection sensor 32, and at the same time, thefilm-forming condition accomplishment detection sensor 35 judges whetherthe film-forming space X is in a vacuum state, that is, the film-formingconditions are reached.

When it is judged that the film-forming conditions are reached, acommand of film-forming control is outputted to the film-formingapparatus 18 during the predetermined period of film-forming time, andfilm-forming control for stopping the film formation is executed in linewith elapse of the corresponding period of time. After that, a closingcommand signal is outputted to the first opening/closing valve operationactuator 23, wherein closing control is executed for the firstopening/closing valve 22 in which a detection signal that thecorresponding first opening/closing valve 22 has been closed is inputtedfrom the first opening/closing detection sensor 32.

Thus, after a film is formed on the work 16 and the firstopening/closing valve 22 is entered into a closed state, a controlcommand by which the ejector operation actuator 42 is caused to beentered into a half removing posture is outputted, and when a detectionsignal detected by the ejector posture detection sensor 41 is inputtedto recognize that atmospheric air has flown into the film-forming spaceX, a mold opening command is outputted to the first mold operationactuator 20 to execute the corresponding mold opening operation, whereinthe series of film-forming processes are finished by the mold openingbeing detected by the mold status detection sensor 31.

Further, the next process control, such as a process for removing thework 16 from the first mold and taking it out by protruding the ejectorbody 38, is carried out. In this connection, where the next processoperation is to take out the work 16, a taking-out robot is applied tothe work 16 which has been half-removed, and the ejector body 38 isfurther protruded in this state to bring the work 16 in a fully removingposture thereof, wherein the taking-out robot catches the work 16 andremoves it from the mold. Thus, it becomes possible to prevent the work16 from dropping from the first mold 36.

In the third embodiment thus embodied, because atmospheric air can flowinto the vacuumed film-forming space X by effectively using the ejectorbody 38, which is provided to take out the film-formed work 16, and theinflow channel 40 thereof, the advantage the mold structure can besimplified is achieved.

In such a mode, there is an advantage in that the ejector means can beeffectively used for the atmospheric air inflow channel and theopening/closing means thereof. However, it is a matter of course thatthe atmospheric air inflow channel and the opening/closing means may beformed in the first mold.

Described above is a useful and effective film-forming mold for avarious types of moldings (work) including headlamps, directionindicators (including side blinkers), tail lamps, etc., which areincorporated in a vehicle, etc., a film-forming method using thecorresponding mold, and a film formation controlling system.

1. A molding and film-forming mold comprising: a first mold thatincludes a first mold surface for forming one surface of a first workand a second mold surface for forming one surface of a second work; asecond mold that includes a first mold surface for forming anothersurface of the first work and a second mold surface for forming anothersurface of the second work, wherein: the second mold includes a thirdmold surface within which film-forming means is incorporated in order toform a film on the another surface of the first work that is supportedby the first mold, and the first mold surface of the first mold supportsthe first work and the second mold surface of the second mold supportsthe second work when the first work and the second work are matched toeach other after the film is formed on the another surface of the firstwork.
 2. The molding and film-forming mold according to claim 1, whereinthe first mold is a movable type mold and the second mold is a fixedtype mold.
 3. The molding and film-forming mold according to claim 1,wherein the film-forming means is one of a spattering apparatus and avacuum deposition apparatus.
 4. The molding and film-forming moldaccording to claim 1, wherein the film-forming means is provided in acylindrical recessed hole having a bottom, which is formed in the secondmold, and a film-forming space is secured between the film-forming meansand the first work.
 5. The molding and film-forming mold according toclaim 1, wherein the film-forming means is provided so as to airtightlyseal a through-hole provided in the second mold, and a film-formingspace is secured between the film-forming means and the first work. 6.The molding and film-forming mold according to claim 5, wherein thesecond mold is provided with a vacuuming flow channel to make thefilm-forming space a vacuum, and first opening/closing means for openingand closing the vacuuming flow channel.
 7. The molding and film-formingmold according to claim 1, wherein a masking portion for masking thefirst work attached to the first mold is provided in the second mold. 8.The molding and film-forming mold according to claim 5, wherein one ofthe first mold and the second mold is provided with an atmospheric airinlet channel for permitting atmospheric air to flow into thefilm-forming space, and second opening/closing means for opening andclosing the atmospheric air inlet channel.
 9. The molding andfilm-forming mold according to claim 8, wherein the atmospheric airinlet channel and the second opening/closing means are provided inejector means for removing a film-formed work from the first mold. 10.The molding and film-forming mold according to claim 8, wherein thesecond mold is provided with third opening/closing means for opening andclosing the film-forming space, which is positioned between thevacuuming flow channel and the atmospheric air flow inlet channel.
 11. Amolding and film-forming method using a mold, comprising, at least, thesequential steps of: work molding of a molded first work and a moldedsecond work by matching a first mold surface of a first mold and a firstmold surface of a second mold and by matching a second mold surface ofthe first mold and a second mold surface of the second mold; workremoving such that the molded first work is left on the first moldsurface of the first mold while the molded first work is removed fromthe first mold surface of the second mold, and the molded second work isleft on the second mold surface of the second mold while the moldedsecond work is removed from the second mold surface of the first mold;mold matching the first mold surface of the first mold onto which themolded first work is left and a third mold surface of the second moldwithin which film-forming means to form a film on the molded first workis incorporated, the third mold surface of the second mold beingdifferent than the first mold surface and the second mold surface of thesecond mold; film-forming for forming the film on the molded first workin a state of the mold matching; opening the first mold and the secondmold; and work adhering of the molded first work with the formed filmand the molded second work by matching the first mold surface of thefirst mold and the second mold surface of the second mold in a statewhere the molded first work is left on the first mold surface of thefirst mold and the molded second work is left on the second mold surfaceof the second mold.
 12. The molding and film-forming method using amold, according to claim 11, wherein the first mold is a movable typeand the second mold is a fixed type.
 13. The molding and film-formingmethod using a mold, according to claim 11, wherein the film-formingmeans is one of a spattering apparatus and a vacuum depositionapparatus.
 14. The molding and film-forming method using a mold,according to claim 11, wherein a vacuuming step to create a vacuum in afilm-forming space between the film-forming means and the molded firstwork is provided between the mold matching step and the film-formingstep.
 15. The molding and film-forming method using a mold, according toclaim 14, wherein the second mold is provided with a vacuuming flowchannel communicating with a vacuum pump to create the vacuum in thefilm-forming space, and first opening/closing means for opening andclosing the vacuuming flow channel, and the vacuuming step is carriedout by opening the first opening/closing means.
 16. The molding andfilm-forming method using a mold, according to claim 11, wherein thesecond mold is provided with a masking portion for masking the moldedfirst work attached to the first mold, and the molded first work ismasked in the mold matching step.
 17. The molding and film-formingmethod using a mold, according to claim 14, wherein one of the firstmold and the second mold is provided with an atmospheric air inflowchannel for permitting atmospheric air to flow into the film-formingspace, and second opening/closing means for opening and closing theatmospheric air inflow channel, and further comprising a firstopening/closing means closing step for closing the first opening/closingmeans and a second opening/closing means opening step for opening thesecond opening/closing means between the film-forming step and theopening step.
 18. The molding and film-forming method using a mold,according to claim 17, wherein the atmospheric air inflow channel andthe second opening/closing means are provided in ejector means forremoving a film-formed work from the first mold, and the secondopening/closing means opening step is carried out in line with removalof the work by the ejector means.
 19. The molding and film-formingmethod using a mold, according to claim 17, wherein the atmospheric airinflow channel is a mold-matching surface between the first mold and thesecond mold, and the second opening/closing means closes the atmosphericair inflow channel by mold matching in the mold matching step, and opensthe atmospheric air inflow channel in the opening step.
 20. The moldingand film-forming method using a mold, according to claim 17, wherein thesecond mold is provided with third opening/closing means for opening andclosing the film-forming space between the vacuuming flow channel andthe second opening/closing means, and a third opening/closing meansclosing step for closing the third opening/closing means is providedduring the steps from an end of the film-forming step to the secondopening/closing means opening step.